Clockspring having non-compliant and compliant roller members

ABSTRACT

A clockspring connector having a clockspring housing, a hub, a chamber defined by the housing, and a carrier member. The clockspring housing includes an inner wall and an outer wall. A flat conductor cable coiled within the clockspring housing. The hub is rotatably mounted within the clockspring housing. The chamber is defined by the clockspring housing. The carrier member is mounted within the chamber. The carrier member has roller members. One of the roller members is a hard roller member and another of the roller members is a compliant roller member. Typically, the hard roller member is positioned at a turn-back portion of the flat conductor cable.

This application is a continuation-in-part of U.S. Ser. No. 09/107,108,filed Jun. 30, 1998, now U.S. Pat. No. 6,012,935 issued Jan. 11, 2000,which is a continuation-in-part of U.S. Ser. No. 08/986,866, filed Dec.8, 1997, now U.S. Pat. No. 5,980,286 issued Nov. 9. 1999, which is acontinuation-in-part of U.S. Ser. No. 08/667,634 filed Jun. 24, 1996,now U.S. Pat. No. 5,865,634 issued Feb. 2, 1999, which is a continuationof U.S. Ser. No. 08/276,954 filed Jul. 19, 1994 now abandoned. Theaforementioned parent applications are hereby incorporated herein byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention pertains to a clockspring connector for enclosingelectrical conductor cables. The invention more particularly concernsthe clockspring connector electrically connects a rotatable electricdevice with a stationary electric device.

2. Discussion of the Background

While the present invention may have multiple applications, the mostprevalent is for use in automobiles. An increasing number of automobileshave airbag crash systems. An airbag is typically located on thesteering wheel facing the driver. The airbag must be in continuouselectrical connection with sensors in the car body. The sensors providean electrical signal to the airbag crash assembly which instantlyinflates the airbag in the event of a crash. Accordingly, there is aneed for an electrical connection between the rotatable portion of theairbag assembly which is mounted to the steering wheel, and theremaining portion of the assembly which is in a stationary position inthe car body. Electrical connections between rotatable and stationaryparts are well known. Typically, an electrical brush rests upon aconductive ring, with one of the parts being rotatable to provide suchrotatable electrical connection. However, there is a risk, particularlyduring the impact of an accident, of a transient failure of electricalconnection with a brush and ring system which result in failure of theentire airbag system crash assembly.

Additionally, airbags are being incorporated into seat belt chestharnesses. Thus, an electrical connection is needed between thestationary portion of the vehicle and the translating seat belt chestharness which is wound and un-wound around a rotating return axis.

Accordingly, a clockspring connector has previously been developed,comprising an outer housing, a rotor member and a multiple ofintermediate housing members for enclosing and connecting the members;the housing and rotor member rotatably associated with one another at aplurality of bearing surfaces. A “clockspring” is located inside theinterconnector. The clockspring of prior art devices includes a singleflat conductor cable having its ends conductively attached to conductorwires which pass out of the interconnector to unite the airbag to thesensing device. For example, U.S. Pat. No. 5,061,195 discloses aclockspring housing and assembly having a single flat conductor cabletherein.

It has also been known in the art to reduce the length of the flatconductor cable in order to reduce cost and needed space within theclockspring housing. For example, U.S. Pat. No. 5,277,604 incorporatesan assembly of at least eight rollers and turned-back portions of theflat conductor cable within the clockspring housing to decrease thelength of the flat cable and also prevent buckling and enhancereliability and smooth rotation of the clockspring connector. Such adesign requires a complex and expensive system of mounting the rollers.Such a design may be expensive and, as well, only accommodates a singleflat conductor cable.

The use of a pair of conductor cables was disclosed in U.S. Pat. No.3,763,455. The conductor cables were carried by an assembly of twentyspacers or rollers. This design also requires a multiplicity of parts,including numerous rollers which add to the assembly time and costs ofthe device.

As more controls are mounted on the steering wheel, more conductors arerequired to pass multiple electrical signals through the clockspringconnector. Prior art clocksprings have included conductor cables havingup to six conductors in each flat cable. The excess of six conductors islimited by the limited width of the flat conductor cable and theprocessing methods of manufacturing the flat cable. Accordingly, thereis needed a clockspring connector which can accommodate more than sixconductors.

Still further, assembling clocksprings is a laborious and costly processthat is prone to error. In particular, the known art requires that theclockspring be assembled from an assortment of components that guideflat ribbon cables in sync with the rotation of the steering wheel.Assembling the various components individually into a clockspring is atedious and labor intensive process.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide for a clockspringthat may readily be assembled and manufactured.

It is still another object of the invention to provide for an integratedcarrier assembly having a frame and which easily assembles within asteering wheel.

It is another object of the present invention to provide a clockspringconnector having a minimal amount of moving parts.

It is a further object of the present invention to provide a clockspringconnector having flat conductor cable of minimal length.

It is another object of the present invention to provide a clockspringhaving a freely and independently rotating carrier member.

It is a further object of the present invention to provide a clockspringconnector that reduces vibration of the flat conductor cable by use of acompliant roller member.

It is yet another object of the invention to provide a durableclockspring.

The above objects and advantages are provided by a clockspring connectorcomprising a housing defining a chamber extending therethrough. Acarrier member positioned within the chamber having a hard roller memberand a plurality of complaint roller members. A flat conductor cablebeing carried by the carrier member. The flat conductor cable having aturned-back portion associated with the hard roller member. A hub havingan inner diameter exit cavity for receiving the flat conductor cable.The housing member receives the hub, the carrier member is mounted onthe hub, and a cover encloses the carrier member and flat flexible cablewithin the housing. The cover having an outer diameter exit cavity.

In an alternative embodiment of the invention, the clockspring providesfor the housing to include a carrier assembly rotatably mounted thereto.The housing itself includes a fixed cover and a base that define achamber. The carrier assembly preferably comprises a frame having one ormore rollers that rotate independently. Within the housing, an innerdiameter region is concentrically defined by a hub and the frame, and anouter diameter region is concentrically defined by the frame and thehousing. The first and second flat ribbon cables are variablydistributed to encircle the hub along either the inner or outer diameterregions. The flat ribbon cables pass and turn-back through the rollersof the frame, so that the portions of each flat ribbon cables located inthe inner and outer diameter regions move in opposite directions. Eachflat ribbon cable includes a slack length that passes through acorresponding roller or roller pair to vary the distribution of the flatribbon cable between the inner and outer diameter. A hard roller memberbeing positioned at a concave surface of the turned-back portion of oneof the flexible flat cables and a compliant roller member beingpositioned at a convex surface of the flexible flat cable at theturned-back portion. The first and second flat ribbon cablesinterconnect to an inner backbone, as incorporated by previousembodiments, that is received by the base and accessible to each flatribbon cable from the inner diameter region. An outer backbone is alsoaccessible to each flat ribbon cable along the outer diameter region,such that the flat ribbon cables may interconnect the inner and outerbackbone within the clockspring. In this way, rotation of the innerbackbone causes the flat ribbon cables to contact and rotate theintegrated carrier assembly. In particular, the slack length of eachflat ribbon cable may contact a roller and rotate the integrated carrierassembly in conjunction with the intake or outtake of flat ribbon cable.Preferably, the slack length of each flat ribbon cable may contact oneor the other roller forming a roller pair that receives each flat ribboncable, thereby forcing the integrated carrier assembly to rotate ineither the clockwise or counterclockwise direction.

These and other features of the invention are set forth below in thefollowing detailed description of the presently preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1 is an exploded perspective view of a clockspring connector;

FIG. 2 is a top view of a clockspring connector in a fully woundposition; and

FIG. 3 is a top view of clockspring connector in a fully unwoundposition;

FIG. 4 is a top view of an alternate embodiment of a clockspringconnector;

FIG. 5 is an enlarged view of a compliant roller member of FIG. 4;

FIG. 6 is a side cut-away view of the clockspring connector of FIG. 4taken along section line 6—6;

FIG. 7 is a top view of a clockspring embodiment of an alternativeintegrated carrier assembly in the unwound position;

FIG. 8 is a top view of another alternate embodiment of a clockspringconnector;

FIG. 9 is an enlarged view of a compliant roller member of FIG. 8;

FIG. 10 is a side cut-away view of the clockspring connector andcompliant roller member of FIG. 9 taken along section line 10—10;

FIG. 11 is a side cut-away view of the clockspring connector and hardroller member of FIG. 8 taken along section line 11—11; and

FIG. 12 is a top view of a clockspring embodiment of an alternativeintegrated carrier assembly in the unwound position.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views, and moreparticularly to FIGS. 8-12 thereof, a clockspring having a hard rollermember and compliant roller members has been created which provides forclockspring performance that is quiet and durable. Firstly, however, theembodiments disclosed in FIGS. 1-7 are discussed so as to introduce andset the stage for the embodiments discussed in FIGS. 8-12.

The clockspring connector is better understood by reference to FIGS. 1-3which show various aspects of a clockspring connector. Turning to FIG.1, a housing 10 receives a hub 20. Mounted on the hub 20 is a carriermember 30. A first flat conductor cable 41 and a second flat conductorcable 42 is carried by the carrier member 30. A cover 50 encloses theflat ribbon cables 41, 42, carrier member 30 and hub 20 within housing10.

The housing 10 includes a ledge 12 upon which the base 22 of hub 20rests. The hub 20 and housing 10 are constructed of materials whichallow the hub 20 to freely rotate within the housing 10 and to reducethe amount of friction between the base 22 and ledge 12 to the greatestextent. Materials such as a teflon tape, silicon material or grease maybe inserted between the base 22 and ledge 12 in order to reduce frictionat these bearing surfaces and all other bearing surfaces of the presentinvention. An inner diameter exit cavity 24 protrudes downwardly fromthe base 22 of hub 20. Inserted within the inner diameter exit cavity 24is an inner diameter backbone 26. The inner diameter backbone 26receives flat conductor cable at its entrance end 27 and insulated wires28 protrude from the exit end 29.

Mounted on the hub 20 and freely and independently rotatable thereon iscarrier member 30. The carrier member 30 is generally a circularlyshaped member being molded of a thermoplastic polymer material. However,any material may be used to form the carrier member 30. The carriermember 30 includes a first roller mounting area 37 and a second rollermounting area 38. Axles 33, 34 protrude upwardly from the rollermounting areas 37, 38, respectively. Roller area walls 35, 36 surroundthe roller areas 37, 38 and are correspondingly shaped to the outerdiameter of first roller 31 and second roller 32. Inner diameter corner65 and outer diameter corner 66 are located at each end of roller areawalls 35, 36. The total circumference of roller area walls 35, 36 may becontrolled by changing the shape of comers 65, 66 in order to controlthe path of the conductor cables 41, 42. By rounding comers 65, 66, thecircumference of walls 35, 36 is reduced and the area which contacts theconductor cables 41, 42 is also reduced. By extending and bringingcomers 65, 66 to a point, the circumference of walls 35, 36 is increasedwhich increases the surface area which contacts conductor cables 41, 42.

First roller 31 is mounted on axle 33 and second roller 32 is mounted onaxle 34 of the carrier member 30. The first and second rollers 31, 32rotate freely and independently on their axles 33, 34. A multiplicity ofnubs 39 a and 39 b protrude from around the carrier member 30 toward thehub 20 or housing wall 15 and provide a surface against which theconductor cables 41, 42 may rub and rotate against. The carrier member30 provides a member for mounting rollers 31, 32 and separating theconductor cables 41, 42 along the outer diameter of the chamber 14 fromthe conductor cables 41, 42 at the inner diameter of the chamber 14.Spring members 62 are molded into the carrier member 30. Spacers 64protrude from spring members 62 and help to keep the carrier member 30positioned axially within the clockspring housing chamber 14. Thehousing chamber 14 is defined by the housing wall 15 around thecircumference of the housing 10. The chamber 14 is further defined bythe hub base 22 at its bottom and cover 50 at the top.

The clockspring includes two flat conductor cables 41, 42. A firstconductor cable 41 and second conductor cable 42 are adjacently coiledaround carrier member 30 within chamber 14 of the housing 10. The flatribbon cables 41, 42 are formed by laminating six conductors parallel toeach other with a pair of insulating films one each side. The use of twoflat ribbon cables 41, 42 having six conductors each provides for atotal of twelve conductors carried by the clockspring. However, morethan two conductor cables could be carried in order to increase thenumber of conductors to an almost limitless combination. The firstconductor cable 41 includes first turned-back U-shaped loop section 43and second conductor cable 42 includes second turned-back U-shaped loopsection 44. First and second conductor cables 41, 42 exit theclockspring at the outer diameter through the outer diameter exit cavity52. Conductor cable tails 46 are folded perpendicularly to the path ofthe conductor cables within the chamber 14 and are received by the outerdiameter exit cavity 52. Outer diameter backbone 54 is received from theother end of the outer diameter exit cavity 52 from the conductor cabletails 46. Entrance cavity 56 of the outer diameter backbone 54 receivesthe first and second conductor cables 41, 42. The conductors of thecables 41, 42 are welded to the corresponding insulated wires 58 whichprotrude from the exit end 59 of outer diameter backbone 54.

Assembly of the clockspring connector having the hub 20 adjacent thehousing 10 occurs in order to allow for the easiest and quickestpossible assembly of the clockspring connector. While the hub 20includes the exit cavity 24 at the inner diameter, the hub 20 is therotatable member which is associated with the steering wheel of anautomobile. Rotation of the steering wheel of the automobilesimultaneously rotates the hub 20. The cover 50 having exit cavity 52 atits outer diameter is placed onto the housing 10 and is the stationarymember of the clockspring connector. The exit cavity 52 at the outerdiameter is associated with the steering column of an automobile and isstationary. Thus, although FIG. 1 shows assembly of the clockspringconnector having the inner diameter exit cavity 24 on the bottom and theouter diameter exit cavity 52 at the top of the assembly; when theclockspring connector is assembled to a steering assembly, it will beinverted so that the inner diameter exit cavity 24 and hub 20 are on thetop of the clockspring connector and the outer diameter exit cavity 52and cover 50 are on the bottom of the clockspring connector.

Operation of the clockspring can more easily be understood by viewingFIG. 2. The housing 10 has mounted therein carrier member 30 and hub 20.Mounted on the carrier member 30 is first roller 31 and second roller32. The clockspring connector is shown in the fully wound positionhaving the majority of the conductor cables 41, 42 coiled around the hub20 at the inner diameter of the chamber 14. First roller 31 is mountedin roller area 37 on axle 33 of the carrier member 30. Second roller 32is mounted in second roller area 38 on axle 34 of the carrier member 30.First conductor cable 41 exits the outer diameter backbone 54 and coilsadjacent to the outer diameter wall 15 of the housing 10. Firstturned-back loop section 43 then coils around first roller 31 and thencoils around the hub 20. Second flat conductor cable 42 exits the outerdiameter backbone 52 and at second turned-back loop 44, coils aroundsecond roller 32 and then onto hub 20 from the opposite side, 180° fromthe position where the first conductor cable 41 coils onto the hub 20.First conductor cable 41′ terminates at the inner diameter backbone 26adjacent second flat conductor cable 42′.

The rotational movement of the steering wheel is transmitted to theclockspring connector through the hub 20 and inner diameter backbone 26.Rotation in the clockwise direction or in direction of arrows 70, 71causes the first flat conductor cable 41 to unwind off of hub 20 andmove to the right at position 100 and rub against wall 35 of the firstroller area 37 of the carrier member 30. Simultaneously, second flatconductor cable 42 unwinds from hub 20 at point 102 and protrudes andrubs against wall 36 of second roller area 38 of carrier member 30. Asthe hub continues to unwind in the clockwise direction, the conductorcables 41, 42 push against walls 35, 36 and force the carrier member 30also to rotate clockwise. As the hub 20 and carrier member 30 rotateclockwise, the first flat conductor cable 41 is spooled out from firstroller 31 to completely encircle the outer diameter of the chamber 14adjacent the wall 15 of the housing 10. Simultaneously, the second flatconductor 42 is spooled out along second roller 32 at a position 180°from the first conductor cable 41, to provide a second coil layeredadjacently to the first conductor cable 41 at the outer diameter of thechamber 14. Rotation of the hub 20 and carrier member 30 continue in theclockwise direction until the flat cables 41, 42 are completely unwoundfrom the hub 10.

The completely unwound condition is shown in FIG. 3. Like numerals forlike elements of FIG. 2 are shown in FIG. 3. The clockspring connector 5is shown in a completely unwound position, i.e., the flat conductorcables 41, 42 are not coiled around hub 20. To wind the clockspringconnector 5, the hub 20 is rotated in a counter-clockwise direction inthe direction of arrows 72, 73. Upon rotation of the hub 20 in acounter-clockwise direction, the first flat cable 41 pulls on the firstroller 31 at first turned-back loop 43 causing the first roller 31 torotate. Simultaneously, second conductor cable 42 pulls on second roller32 at second turned-back loop 44 causing the second roller 32 to rotatein clockwise direction. The pulling of the first cable 41 and the secondcable 42 on the first and second rollers 31, 32 causes the carriermember 30 to rotate in a counter-clockwise direction. As the hub 20 andcarrier member 30 continue to rotate counter-clockwise, the first andsecond conductors 41, 42 are uncoiled from the outer diameter of thechamber 14 and become coiled again onto the hub 20. It can be seen thatin the completely unwound position, the coils are positioned along theouter diameter of the chamber 14 in a first layer 81, a second layer 82,a third layer 83, and a fourth layer 84. The first conductor cable 41and the second conductor cable 42 are alternatingly layered; whereinfirst layer 81 and third layer 83 are the first conductor cable 41 andthe second layer 82 and fourth layer 84 are the second conductor cable42. Upon the first rotation of the hub 20 in the counter-clockwisedirection, layer 81 is taken up from the outer diameter of the chamberonto the hub 20 by first roller 31. Simultaneously, second layer 82 istaken up by second roller 32. Upon a second rotation, third layer 83 istaken up by the continued rotation of first roller 31 in thecounter-clockwise direction and fourth layer 84 is taken up by secondroller 32. This alternating take-up sequence is correspondingly achievedalong the inner diameter of the chamber 14 by winding the clockspringconnector in the clockwise direction spooling first and second conductorcables 41, 42 onto the hub 20.

Turning to FIG. 4 an alternate clockspring 103 embodiment is shownincluding a housing 110 having a hub 120. Mounted on the hub 120 is acarrier member 130. A first flat conductor cable 141 is carried by thecarrier member 130. A cover encloses the carrier member 130 and hub 120within the housing 110. The housing 110 is constructed of materialswhich allow the hub 120 to freely rotate within the housing 110 and toreduce the amount of friction between the base 122 of the housing 110.Material such as teflon tape, silicon material or grease may be insertedbetween the base 122 and the housing 110 in order to reduce the frictionat these bearing surfaces. Similarly, such materials may be used toreduce friction between the carrier member 130 and the housing 110. Aninner diameter exit area 126 receives the flat conductor cable 141 andthe tape or flat conductor cable is attached to a backbone (not shown)which connects the flat conductor cable to external electrical wires.

The carrier member 130 is generally a hollow cylindrically shaped membermolded of a thermoplastic polymer material. However, any material may beused to form the carrier member 130. The carrier member 130 includes afirst roller mounting area 137 and a second roller mounting area 187. Inan embodiment the carrier member 130 may include six roller mountingareas and six roller members 131. However, any number of roller mountingareas and rollers can be used. Axles 133 protrude upwardly from theroller mounting area 137. Roller area walls 135, 136 surround the rollerareas 137 and are correspondingly cylindrically shaped to the outerdiameter of the roller member 131. The roller member 131 is mounted onaxle 133 and is retained on the axle by arm 160. The arm 160 isintegrally molded with the axle 133. The arm 160 extends out from theaxle 133 beyond the inner-diameter of the roller member 131. The rollermember 131 is formed of a elastic, compliant material such as rubber orneoprene. The complaint material allows the roller member 131 tomaximize the compression forces that are applied against the flat ribboncable 141 thus urging the ribbon cable 141 against the outer wall of thechamber 182 and the inner wall of the chamber. For example, a rubberO-ring manufactured by Apple Rubber Products, Inc. is used in anembodiment and has durometer measure of 70 and a diameter of 19.5 mm andprovides a compression force of 0.15 grams against the flat ribbon cable141 when the roller member 131 is deformed by less than 20% of itsoriginal, undeformed shape. The diameter of the roller member 131 isapproximately equal to the width of the chamber 182 ±0.100 inch. Thewidth of the chamber is defined by the shortest distance between theinner wall 152 and outer wall 151 of the housing 110.

In another embodiment the roller member 131 maybe formed of a lowfriction and rigid material at its inner diameter and a high frictionand compliant material along its outer diameter. The roller having amultiple composition provides for maximum friction against the flatribbon cable 141 while allowing for some compression. Having the rigidmaterial at the center of the roller member eliminates the possibilityof permanent deformation of the roller member 131. The roller member 131rotates freely and independently on the axle 133 due to the lubricity ofthe mating materials. The orientation of multiple roller members mountedon the carrier member 130 provides for a continuous compression of theflat ribbon cable 141 against the inner wall 152 and outer wall 151around the entire diameter of the clockspring housing 110. The rollermembers 131 have an outer diameter approximately equal to the widthbetween the inner wall 152 and outer wall 151. The roller member 131 inthe first roller area 137 also provides the function of a turn back loopin order to guide the flat ribbon cable 141 in a U-shape from the hub120 through the first roller area 137 and turning back to be guidedalong the outer wall 151. The clockspring shown in FIG. 4 discloses onlya single flat ribbon cable 141. However, in an alternative embodimentthe present design may also incorporate multiple flat ribbon cablesbeing carried by the carrier member 130 and the roller members 131.

The clockspring 110 in FIG. 4 is shown in the full counter-clockwiseposition having the flat ribbon cable 141 spooled onto the outer wall151 of the housing 110. As the hub 120 is rotated in a clockwisedirection the flat ribbon cable 141 moves through the first roller area137 and is coiled onto the inner wall 152 of the hub 120. As the flatribbon cable 141 moves from being coiled onto the outer wall 151 to theinner wall 152 the thickness of the coil tape on the outer wall 151 isreduced and the thickness of the coiled flat ribbon cable 141 on theinner wall 152 is increased. In other words the gap between the rollermember 131 and the inner and outer walls 151, 152 changes as the flatribbon cable 141 is spooled from the outer wall 151 to the inner wall152. Although the gap between the roller member 131 and the walls 151,152 varies, the compliant roller member 131 maintains a constantcompression against the flat ribbon cable 141, regardless of how manylayers of the coiled flat ribbon cable are located on either the outeror inner wall 151, 152. This procedure is reversed when the hub 120 isrotated in the counter-clockwise direction.

Turning to FIG. 5, an enlarged view of second roller area 187 is shown.The roller member 131 is mounted on axle 133 and is maintained thereonby arms 160, 161. The roller member 131 is mounted on carrier member 130which is mounted within the housing 110 of the clockspring between theouter wall 151 and inner wall 152. The flat ribbon cable 141 is shownhaving a first layer 191 and a second layer 192 coiled against the outerwall 151 of the housing 110. The two coiled layers 191 and 192 of theflat ribbon cable 141 cause the roller member 131 to compress and forman ovoid shape. The diametral distance measured from where points of theroller member 131 contact the inner and outer walls 151, 152 being isless than the diametral distance measured between points of the rollermember 131 at points 201 and 202 where the roller member 131 is adjacentthe roller area walls 136, 137. The roller member 131 is also offsettoward the inner wall 152 so that the inner diameter of the rollermember 131 forms a first gap 210 between the inner diameter of theroller member 131 and the axle 133 that is greater than a second gap 211formed between the inner diameter of the roller member and the axle 133.In a preferred embodiment the roller member 131 includes an innerdiameter radius that is larger than the radius of the axle 133, so thatsuch an offset condition may be achieved. Consequently, when the hub 120is rotated and the flat ribbon cable 141 is coiled on the inner wall152, the roller member 131 will be offset in the other direction towardthe outer wall 151 and the first gap 210 will be less than the secondgap 211. Similarly, the ovoid shape of the roller member 131 will bemaintained in order to continue to provide compression of the rollermember 131 against the flat ribbon cable 141 coiled onto the inner wall152 of the housing 110. Therefore, it may be understood throughout theentire rotation of the hub and the winding and the unwinding of the flatribbon cable 141 a constant pressure will be applied against the flatribbon cable 141 compressing it against either the inner 152 or outer151 wall of the housing 110. This improved system provides for a quietclockspring operation which avoids vibrations of the flat ribbon cable141 that cause noise.

Turning to FIG. 6 a side elevation cut-away view of FIG. 4 taken at line6—6 is shown. The housing 110 is shown having hub 120 mounted thereonforming a cavity 182 in which the carrier member 130 is mounted. Rollermember 131 is mounted on axle 133 and maintained thereon by arms 161,162. As the clockspring is in its full counter-clockwise position,multiple layers of the flat ribbon cable 141 are coiled along outer wall151 and a single coil of the flat ribbon cable 145 is located alonginner wall 152 of the housing 110. In this orientation it can be seenthat the first gap 210 between the inner diameter of the roller member131 and the outer diameter of a first side 191 the axle 133 is greaterthan the second gap 211 on the opposed second side 192 of the axle 133.As discussed above, the roller member 131 being formed of a compliantmaterial provides for the roller member 131 providing a constantcompression force against the flat ribbon cable 141, 145 throughout theunwinding and winding of the flat ribbon cable onto the inner wall 151to the outer wall 151 of the clockspring housing 110.

It can be seen that two flat conductor cables can be easily wound withminimal components incorporated within the clockspring housing and withminimal length of flat conductor cable.

In still another clockspring 203 embodiment, FIG. 7 shows an integratedcarrier assembly 230 for employing rotatably mounted rollers to guideone or more flat ribbon cables. The integrated carrier assembly 230differs from previous embodiments in that it includes preassembledcomponents integrated as one unit for assembly purposes. As will bedescribed in greater detail, the integrated carrier assembly 230 of thepreferred embodiment includes a frame 260 with rollers or rollerassemblies mounted thereto. As with previous embodiments, the integratedcarrier assembly 230 resides with a chamber 214 defined by theclockspring housing 210. The preferred integrated carrier assembly 230includes a frame 260 having pairs of rollers for guiding the flat ribboncables thereto. In general, the integrated carrier assembly 230 operatesin similar fashion to previous clocksprings described herein.Accordingly, FIG. 7 shows that the integrated carrier assembly 230rotatably mounts to the hub 220, with the cover 250 fixedly mounted overthe housing 210 to enclose the hub 220 and integrated carrier assembly230. The housing 210 is also constructed of materials which allow thehub 220 to freely rotate therein in a manner that reduces frictionbetween the base (shown as numeral 22 in FIG. 1) and housing 210. Tothis end, materials such as Teflon tape, silicon material orconventional grease may be injected between the base 222 and the housing210. In similar fashion, the integrated carrier assembly 230 isrotatably secured to the housing 210 on the hub 220.

With further reference to FIG. 7, the frame 260 surrounds the hub 220and supports a plurality of rotatably attached rollers that maintain aguiding presence on the flat ribbon cables 240, 241. The frame 260 isoblong and contoured to extend across the chamber 214, with one or moreroller assemblies employing rollers that guide the flat ribbon cables240, 241. In the preferred embodiment, a first and second pair ofrollers 231, 231 and 232, 232 oppose one another across the frame 260,with each pair of rollers comprising two adjacent rollers. However, itshould be readily apparent to one skilled in the art that more or lessrollers may be used in similar or alternative arrangements. The rollersare rotatably secured to the frame 260 by corresponding first and secondconnector forks 238, 238 and 239, 239 that unitarily extend from theframe 260 and engage each roller 231 and 232 about the axle to allowfree rotation. For reference, an inner diameter region may be defined asthe concentric area between the integrated carrier assembly 230 and hub220, while the outer diameter region is defined as the concentric areabetween the housing 210 and integrated carrier assembly 230. The rollers231, 232 spool the flat ribbon cables 240, 241 from the inner diameterregion to the outer diameter region and thereback. Preferably, therollers comprise solid plastic, but may also include compliant rollersdiscussed elsewhere in this application may be substituted in thisembodiment.

As with previous embodiments, the flat ribbon cables 240, 241electrically connect two conductive backbones or conductive surfaceswithin the housing, where the first backbone is received by the base andis rotatable therewith to transmit the motion of the steering wheel. Forpurposes of this particular embodiment, the ribbon cables 240, 241connect the inner diameter backbone 226 with the outer diameter backbone254, in a manner described with previous embodiments herein. Each flatribbon cable 240, 241 is distributed to include a portion within theinner and outer diameters, where each flat ribbon may pass and turn-backthrough the roller assemblies 231, 232 to distribute their respectivelengths between the inner and outer diameters. In this way, when theflat ribbon cables 240, 241 distribute upon rotation of the innerbackbone 226, the portions of the respective flat ribbon cables 240,241within the inner and outer diameter each move in opposite directionswith respect to one another. Each flat ribbon cable 240, 241 may alsohave a slack portion that is variable with rotation of the innerbackbone 226, and is defined approximately to be the cable lengthpositioned at any given moment between the rollers of each rollerassembly 231, 232. With rotation of the inner backbone 226, the flatribbon cables 240, 241 increasingly distribute between the inner orouter diameter region, depending on whether the clockspring is beingwound or unwound. FIG. 7 shows in greater detail one preferredconfiguration of the clockspring, with the flat ribbon cables 240, 241in the unwound position such that the amount of each flat ribbon cable240, 241 is maximized along the outer diameter region.

Since the arrangement of flat ribbon cables 240, 241 may equally beshared between the inner and outer diameter regions, the embodiment willbe described with reference to the wound position depicted in FIG. 7. Itshould be apparent to one skilled in the art that the distribution andmotion of the flat ribbon cable 240, 241 from the wound to the unwoundposition is substantially similar or equivalent to FIGS. 2 and 3 and theaccompanying text. This embodiment varies from previous embodiments byproviding an improved mechanism for guiding and supporting one or moreflat ribbon cables within the housing. Accordingly, FIG. 7 shows thateach flat ribbon cables 240, 241 may interconnect with the innerbackbone 226 to partially encircle the hub 220 along the inner diameter.Both flat ribbon cables 240, 241 interconnect with the inner backbone226, and extend to and encircle about the outer diameter from opposingends of the frame 260. As such, the flat ribbon cable 241 is shown to belonger than the other cable to provide for the extra length needed toencircle the hub 220 an extra 180 degrees.

As with previous embodiments, rotation of the steering wheel allows theinner backbone 226 to force the flat ribbon cables 240, 241 to variablydistribute among the inner or outer diameter regions. With respect tothe embodiment of FIG. 7, the steering wheel may be rotated in theclockwise direction to wind the flat ribbon cables 240, 241 about thehub 220. The winding motion forces the excess flat ribbon cables 240,241 through the respective pair of rollers 231, 231, and 232, 232. Ingeneral, each flat ribbon cable 240, 241 slackens as it passes throughthe respective rollers 231, 231 and 232, 232. The slack length in turnforcibly engages the roller pairs and thereby provides a reactive forcethat rotates the carrier member 230 in conjunction with the rotation ofthe inner backbone 226. In this way, the motion of the carrier member230 positions the rollers 231, 231, and 232, 232 to intake the flatribbon cable from the outer diameter region, so that the flat ribboncables 240, 241 cannot pinch or radially pull inwards with successiverotations of the inner backbone. In this way, the flat ribbon cables240, 241 may be fully wound from the unwound position about the hub 220,such that all excess cable resides in the inner diameter region.

It should be apparent to one skilled in the art that while the flatribbon cables 240, 241 are preferably slack when passing through therespective rollers 231, 232, a taught engagement between the rollers andflat ribbon cables 240, 241 is also contemplated. In a taughtengagement, each flat ribbon cable 240, 241 pulls one of the rollers inthe pair of rollers 231, 232 as it passes from the outer to the innerdiameter region, with little excess slack forming between the rollers.The pulling motion of the flat ribbon cables 240, 241 through therollers 231 and 232 also causes the reactive force that rotates theintegrated carrier assembly 230 in conjunction with the intake of flatribbon cables.

Based on the configuration of FIG. 7, the flat ribbon cables 240, 241unwind from the inner diameter when the inner backbone 226 is rotated inthe counterclockwise direction. The counterclockwise rotation of theclockspring pushes the flat ribbon cables 240, 241 to unwind from theinside to the outside diameter regions. The unwinding rotation causesthe flat ribbon cables 240, 241 to slack while passing through rollers231, 231 and 232, 232. In turn, the pushing motion of the flat ribboncables 240, 241 causes the respective slack lengths to combine andforcibly contact the roller pairs and/or the integrated carrier assembly230, thereby rotating the integrated carrier assembly 230 in thecounterclockwise motion. In this way, the inner backbone 226 may berotated in the clockwise or counter clockwise direction to variablydistribute the excess length of each flat ribbon cable 240, 241 to andfrom the inner and outer diameter regions.

As with previous embodiments, this embodiment provides for the flatribbon cables 240, 241 to radially compress and reduce the slidingfriction that cause noise. However, this embodiment provides onesignificant improvement over the prior art in that it provides for theflat ribbon cables 240, 241 to compress only within the inner diameterregion. As such, this embodiment avoids the creation of folds andfracture points that tend to form when the flat ribbon cables arecomprised along the outer diameter region. More specifically, the flatribbon cables 240, 241 are confined within the small concentric spacebetween the frame 260 and hub 220, which allows the flat ribbon cables240, 241 to compress against one another and the frame/hub within theinner diameter region. In this manner, the invention reduces the amountof noise that often results from transferring the flat ribbon cables240, 241 between the inner and outer diameter regions.

A method of assembling the clockspring of this invention is alsoprovided for this embodiment. The method includes providing a housinghaving a fixed cover and a rotatable base, the housing receiving a firstand second conductive backbone, the first conductive backbone receivedby the base to be rotatable therewith and with the steering system. Inaddition, the method includes rotatably mounting the hub 220 to thehousing 210 to be freely rotatable with respect to the housing, androtatably mounting the integrated carrier assembly 230 to be freelyrotatable with respect to the hub 220 and the housing 210. The method offurther includes distributing the first flat ribbon cable 240 in thehousing 210 to interconnect the first and second backbone so that aportion of the first flat ribbon cable is distributed in the regionbetween the frame and the hub, and another portion of the flat ribboncable is distributed between the housing and the frame. The method mayalso include distributing a second flat ribbon cable 241 insubstantially similar fashion, and for compressing the first and secondflat ribbon cable 240, 241 against the hub with the frame 260. The flatribbon cables may be compressed by dimensioning the frame 260 withrespect to the hub 220 to provide for the inner diameter regiontherebetween to be sufficiently narrow to compress each flat ribboncable. Finally, the method of assembly may provide for securing theassembled clockspring to a steering system in a manner known andpracticed in the art.

While this embodiment preferably employs a design with two flat ribboncables, it should be readily apparent to one skilled in the art that theintegrated carrier assembly 230 may accommodate a single flat ribboncables design by providing only one pair of rollers. Likewise,additional roller pairs may be employed to incorporate three or moreflat ribbon cables in the clockspring. The use of more or less flatribbon cables is generally dictated by the number of closed circuitsrequired within the steering wheel, and not by limitations of thisinvention.

Thus, Applicants' previous embodiments included clocksprings havingroller members which were all hard and other embodiments includedclocksprings having roller members which were all compliant.

Briefly, problems exist with current clockspring designs that haveresulted in rubbing or scraping of the internal parts of theclockspring, which manifests itself as noise, wear on the components,and increased parasitic torque which must be overcome when turning thesteering wheel. Noise emanating from the clockspring is a majorcomplaint of occupants in the passenger compartment of automobiles.

The clockspring structure according to the present invention greatlyreduces the amount of rubbing and scrapping of internal components ofthe clockspring. Thus, providing for a clockspring which is more quietthan previous clockspring designs.

Applicants have found, hard roller members are substantially rigid andas such they maintain the flat flexible cable in well establishedlocations, however, backlash or clearance exists between the hard rollermembers, the flat flexible cable, and the walls of the housing, thusincreasing noise, but decreases torque. Additionally, the hard rollermembers have excellent resistance against wear and in conjunction withthe polyester insulating layers of the flat flexible cable exhibitexcellent lubricity thus reducing friction.

Applicants have found, compliant roller members in conjunction with thepolyester insulating layer of the flat flexible cable exhibit largeamounts of friction between the two surfaces thus the compliant rollermembers urge the flat flexible cable against the housing of theclockspring, thus the compliant roller members provide for quietoperation of the clockspring. However, the torque required to rotate thehub relative to the housing is increased. Additionally, the compliantroller member located at the turned-back portion of the flat flexiblecable becomes worn with use and the conductors of the flat flexiblecable are susceptible to breakage due to the non-constant radiusprovided by the compliant roller member.

Applicants have combined the best features of the preceding embodimentsand have provided for a clockspring which is durable, quiet, and has lowresidual torque. FIGS. 8-11 show a preferred embodiment of theinvention. FIG. 8 is a top plan view of the clockspring 303 of theinvention. Clockspring 303 is similar to clockspring 103 shown in FIGS.4-6 except that clockspring 303 has a hard, non-compliant orsubstantially rigid roller member 331 located at the turn-backed portionof the flexible flat cable 141. The remaining roller members arecompliant roller members 131 which conform to the previous descriptionof such roller members in the previous embodiment.

The hard roller member 331 is made of a nylon or acetal. A preferredmaterial of construction is an acetal homopolymer sold under the tradename DELRIN and produced by E.I. du Pont de Nemours and Company. Thehard or substantially rigid roller member 331 provides excellentstiffness, dimensional stability, strength, resistance against wear, andsuperior lubricity when sliding against flat flexible cable.

FIG. 11 is an enlarged cross-sectional view of the hard roller member331 taken along section line 11—11 of FIG. 8. Axles 133 protrudeupwardly from the roller mounting area 137 (shown in FIG. 8). Rollerarea walls 135, 136 (shown in FIG. 8) surround the roller areas 137 andare correspondingly cylindrically shaped to the outer diameter of thehard roller member 331. FIG. 11 clearly shows the clearance presentbetween the inside diameter of the hard roller member 331 and theoutside diameter of the axle 133. The materials of construction of theaxle 133 and of the hard roller member 331 are such that a great amountof lubricity is present between the two parts. Thus, even when theflexible flat cable 141 pushes the hard roller member 331 against theaxle 133, the hard roller member 331 and the axle 133 slide relative toeach other without being impeded with much friction. Furthermore, evenwhen the flexible flat cable 141 pushes the hard roller member 331against the axle 133, the outer radius of the hard roller member 331contacts the flexible flat cable 141 and not the arms 160, 161, 162.Since the hard roller member 331 is substantially rigid it maintains theflexible flat cable 141 to a nearly constant radius in the region of theturned-back portion. As such the conductors of the flexible flat cable141 are exposed to uniform amounts of bending and thus the fatiguefailures of the conductors are reduced and the operational life of theclockspring is extended. Additionally, the outside diameter of the hardroller member 331 is smaller than the outside diameter of the compliantroller members 131. The outside diameter dimension of the hard rollermember 331 is dimensioned so as to provide clearance between the walls151, 152 of the chamber 182, and the flexible flat cables 141,142.

As shown in FIG. 8, the hard roller member 331 is mounted on axle 133and is retained on the axle by arm 160. The arm 160 is integrally moldedwith the axle 133. The arm 160 extends out from the axle 133 beyond theinner-diameter of the roller member 331. Since the hard roller member331 is substantially rigid, the hard roller member 331 is rocked orpivoted so as to have its inside diameter to pass by the arm 160.

Turning to FIG. 9, an enlarged view of second roller area 187 is shown.The roller member 131 is mounted on axle 133 and is maintained thereonby arms 160, 161. The roller member 131 is mounted on carrier member 130which is mounted within the housing 110 of the clockspring between theouter wall 151 and inner wall 152. The flat ribbon cable 141 is shownhaving a first layer 191 and a second layer 192 coiled against the outerwall 151 of the housing 110. The two coiled layers 191 and 192 of theflat ribbon cable 141 cause the roller member 131 to compress and forman ovoid shape. The diametral distance measured from where points of theroller member 131 contact the inner and outer walls 151, 152 being isless than the diametral distance measured between points of the rollermember 131 at points 201 and 202 where the roller member 131 is adjacentthe roller area walls 136, 137. The roller member 131 is also offsettoward the inner wall 152 so that the inner diameter of the rollermember 131 forms a first gap 210 between the inner diameter of theroller member 131 and the axle 133 that is greater than a second gap 211formed between the inner diameter of the roller member and the axle 133.In a preferred embodiment the roller member 131 includes an innerdiameter radius that is larger than the radius of the axle 133, so thatsuch an offset condition may be achieved. Consequently, when the hub 120is rotated and the flat ribbon cable 141 is coiled on the inner wall152, the roller member 131 will be offset in the other direction towardthe outer wall 151 and the first gap 210 will be less than the secondgap 211. Similarly, the ovoid shape of the roller member 131 will bemaintained in order to continue to provide compression of the rollermember 131 against the flat ribbon cable 141 coiled onto the inner wall152 of the housing 110. Therefore, it may be understood throughout theentire rotation of the hub and the winding and the unwinding of the flatribbon cable 141 a constant pressure will be applied against the flatribbon cable 141 compressing it against either the inner 152 or outer151 wall of the housing 110. This improved system provides for a quietclockspring operation which avoids vibrations of the flat ribbon cable141 that cause noise.

Turning to FIG. 10, a side elevation cut-away view of FIG. 9 taken alongsection line 10—10 is shown. The housing 110 is shown having hub 120mounted thereon forming a cavity 182 in which the carrier member 130 ismounted. Roller member 131 is mounted on axle 133 and maintained thereonby arms 161, 162. As the clockspring is in its full counterclockwiseposition, multiple layers of the flat ribbon cable 141 are coiled alongouter wall 151 and none of the flat ribbon cable 145 is located alonginner wall 152 of the housing 110. In this orientation it can be seenthat the first gap 210 between the inner diameter of the roller member131 and the outer diameter of a first side 191 the axle 133 is greaterthan the second gap 211 on the opposed second side 192 of the axle 133.As discussed above, the roller member 131 being formed of a compliantmaterial provides for the roller member 131 providing a constantcompression force against the flat ribbon cable 141, 145 throughout theunwinding and winding of the flat ribbon cable onto the inner wall 151to the outer wall 151 of the clockspring housing 110. In a preferredembodiment, as discussed earlier, the compliant roller has a durometermeasurement of 70.

In still another clockspring embodiment, FIG. 12 shows an integratedcarrier assembly 230 for employing rotatably mounted rollers to guideone or more flat ribbon cables. The clockspring 403 is almost the sameas clockspring 203 shown in FIG. 7. The assembly and mode of operationof the two clocksprings 203, 403 are the same. The difference betweenthe two clocksprings is the design of the roller members. Theclockspring 203 of FIG. 7 has roller members 231, 232 which are made ofa rigid plastic. In FIG. 12, the clockspring 403 has substantially rigidor hard roller members 431, 432 at the turned-back portion of the flatribbon cables 240, 241. The difference between the clocksprings existsin the use of complaint roller members 433, 434 which are made of acompliant material such as rubber or neoprene. The compliant rollermembers 433, 434 can be made of a hard material that has an outercoating of compliant material. The hard roller members 431, 432 arepreferably made of DELRIN.

The hard roller members 431, 432 operate the same way as the hard rollermembers of clockspring 203 shown in FIG. 7 and the same as the hardroller member 331 shown in FIGS. 8-11. Hard roller member 431 isattached to connector fork 239. Hard roller member 432 is attached toconnector fork 238. Compliant roller member 433 is attached to connectorfork 239. Compliant roller member 434 is attached to connector fork 238.

The compliant roller members 433, 434 provide the ability to press theflat ribbon cables 240, 241 against the inner wall at the outer diameterof the housing 210. Thus, noise is kept to a minimum since the flatribbon cables 240, 241 are not able to move and vibrate in the vicinityof the compliant roller members 433, 434. Additionally, as an option,the compliant roller members 433, 434 can be oversized so as to placethe flat ribbon cables 240, 241 in a state of compression at the innerwall at the inner diameter of the housing (not shown).

As shown in FIG. 12 the hard roller member 431 faces and opposes thecompliant roller member 433. Hard roller member 431 faces and isadjacent to a concave surface of the first flat ribbon cable at theturned-back portion. Compliant roller member 433 faces and is adjacentto a convex surface of the first flat ribbon cable at the turned-backportion. The function and positioning of hard roller member 432,compliant roller member 434, and the second flat ribbon cable aresimilar.

When the hub 220 or backbone 226 is rotated in a clockwise direction,when looking at FIG. 12, the backbone 226 pulls the first and secondflat ribbon cables in a clock-wise direction. The first flat ribboncable imparts a force on the hard roller member facing the concavesurface of the first flat ribbon cable and thus causes the integratedcarrier assembly 230 to rotate in the clock-wise direction.

When the backbone 226 of the hub 220 is rotated in a second directionopposite to the first direction, i.e. counter-clock-wise, the backbone226 rotates in a counter-clock-wise direction which rotates the firstflat ribbon cable 240 in a counterclock-wise direction. The convexsurface of the first flat ribbon cable 240 imparts a force on thecompliant roller member facing the convex surface. Thus, the integratedcarrier assembly 230 is then caused to rotate in the counter-clockwisedirection. The rolling of the first and second flat ribbon cablesagainst the compliant roller members 433, 434 greatly reduces thesliding and rubbing of components within the clockspring. Thus, thedesign greatly reduces the amount of noise emanating from theclockspring. Conversely, the rolling and sliding of the first and secondflat ribbon cables against the hard roller members 431, 432 increasessliding and rolling between the flat ribbon cables and the hard rollermembers and hence reduces friction and thus reduces parasitic torque.Additionally, the hard roller members 431, 432 maintain a nearlyconstant radius at the turned-back portion, thus the flat ribbon cableshave a longer life since the conductors will not break as often. Thus,the clockspring 403 greatly reduces the amount of noise emanating fromthe clockspring and increases the durability of the clockspring.

While this embodiment preferably employs a design with two flat ribboncables, it should be readily apparent to one skilled in the art that theintegrated carrier assembly 230 may accommodate a single flat ribboncables design by providing only one pair of rollers. Likewise,additional roller pairs may be employed to incorporate three or moreflat ribbon cables in the clockspring. The use of more or less flatribbon cables is generally dictated by the number of closed circuitsrequired within the steering wheel, and not by limitations of thisinvention.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, theinvention may be practiced otherwise than as specifically describedherein.

What is claimed is:
 1. A clockspring connector comprising: a clockspringhousing; a flat conductor cable coiled within the clockspring housing,the flat conductor cable having a turned-back portion; a hub rotatablymounted within the clockspring housing; a chamber defined by theclockspring housing; and a carrier member mounted within the chamberhaving a plurality of roller members of substantially circular crosssection, and wherein one of the plurality of roller members is asubstantially non-compliant roller member, the substantiallynon-compliant roller member being located adjacent to a concave surfaceof the turned-back portion of the flat conductor cable, and wherein atleast one of the plurality of roller members is a substantiallycompliant roller member.
 2. The clockspring connector according to claim1 wherein the clockspring housing has an inner wall and an outer wall,and wherein the chamber has a width defined by the shortest distancebetween the inner and outer wall, and wherein the at least onesubstantially compliant roller member is formed of a compliant materialhaving a diameter approximately equal to said width ±0.100 inch, andwherein the at least one substantially compliant roller member applies acompression force against the flat conductor cable oriented on both theinner wall and the outer wall of the clockspring housing.
 3. Theclockspring connector according to claim 2 wherein the at least one ofthe plurality of roller members is a substantially compliant rollermember includes five substantially compliant roller members.
 4. Theclockspring connector according to claim 1 wherein the at least one ofthe plurality of roller members is a substantially compliant rollermember includes five substantially compliant roller members.
 5. Theclockspring according to claim 1 wherein the substantially non-compliantroller member is made of a substantially rigid material.
 6. Theclockspring according to claim 5 wherein the at least one substantiallycompliant roller member is made of a substantially compliant material.7. The clockspring according to claim 1 wherein the substantiallynon-compliant roller member is made of an acetal homopolymer material.8. The clockspring according to claim 7 wherein the at least onesubstantially compliant roller member is made of a rubber material. 9.The clockspring according to claim 7 wherein the at least onesubstantially compliant roller member is made of a neoprene material.10. The clockspring according to claim 6 wherein the flat conductorcable has insulating layers made of polyester material.
 11. Theclockspring according to claim 10 wherein the carrier has an axle, andwherein the substantially non-compliant roller member is mounted aboutthe axle.
 12. The clockspring according to claim 11 wherein the carrieris made of a polymer material, and wherein the carrier is substantiallyrigid.
 13. The clockspring according to claim 1 wherein thesubstantially compliant roller member is made of a material having adurometer measurement of
 70. 14. The clockspring according to claim 1wherein the substantially compliant roller member deflects substantiallytwenty percent of its non-deformed shaped in a diametral direction whensubject to a force of substantially 0.15 grams.
 15. A clockspringconnector comprising: a clockspring housing; a first flat conductorcable coiled within the clockspring housing; a second flat conductorcable coiled within the clockspring housing; a hub rotatably mountedwithin the clockspring housing; a chamber defined by the clockspringhousing; and a carrier member mounted within the chamber having aplurality of roller members of substantially circular cross section,wherein two of the plurality of roller members are substantiallynon-compliant roller members, and wherein two of the plurality of rollermembers are substantially compliant roller members, and wherein a firstsubstantially non-compliant roller member of the two substantiallynon-compliant roller members faces a concave surface of the first flatconductor cable, and wherein a first substantially compliant rollermember of the two substantially compliant roller members faces a convexsurface of the first flat conductor cable, and wherein a secondsubstantially non-compliant roller member of the two substantiallynon-compliant roller members faces a concave surface of the second flatconductor cable, and wherein a second substantially compliant rollermember of the two substantially compliant roller members faces a convexsurface of the second flat conductor cable.
 16. The clockspringconnector according to claim 15 wherein the first substantiallynon-compliant roller member is adjacent to the first substantiallycompliant roller member.
 17. The clockspring connector according toclaim 16 wherein the second substantially non-compliant roller member isadjacent to the second substantially compliant roller member.
 18. Theclockspring connector according to claim 15 wherein the secondsubstantially non-compliant roller member is adjacent to the secondsubstantially compliant roller member.
 19. The clockspring according toclaim 15 wherein the substantially non-compliant roller members are madeof a substantially rigid material.
 20. The clockspring according toclaim 19 wherein the substantially compliant roller members are made ofa substantially compliant material.
 21. The clockspring according toclaim 15 wherein the substantially non-compliant roller members are madeof an acetal homopolymer material.
 22. The clockspring according toclaim 21 wherein the substantially compliant roller members are made ofa rubber material.